Posted from the "life of a blade thread:
Thanks for the link to your thread. I like the Dremel by hand idea - just don't count the teeth (well, till after the job is done :) ). And yes, no way to set them. The outfit in town had a machine that would sharpen and set but couldn't make money with it - blades were a little cheaper then, but labor is higher now. I think we were paying $12/blade, 141" 3T 3/4". They are ~$20 US now. Just bought 20 of them from Starrett. Mostly it wouldn't pay to do it by hand except in a pinch if there wasn't a new one handy. Main thing is to sharpen each tooth the same amount - so they stay the same length/height and all do the same work.
I visited a machine shop in Fresno some years back where a guy was doing circular saw blades by hand. I asked why they didn't use a machine and he replied that the result wasn't as good - machine leaves a ragged edge, not like hand filing - clean and sharp. File, file, file, tap, turn, file, file, file... he was very fast with it, perfect job in a few minutes. They probably had a machine to set the teeth - didn't ask though. A lost art now I think, around here anyway.
When a blade breaks on the 20" saw it makes a very loud bang - gets your heart going. Sometimes we cut round things. Round objects like to roll into the blade and bind it. Saw has a 3 phase 5hp motor - it doesn't stop, so the blade breaks after embedding itself in the work. I visited a sawmill in Alpine Arizona once. They had a bandsaw - 20' loop maybe? Operator sat next to the work in a cab with plexiglass windows. I think the idler wheel was mostly upstairs. They did the sharpening up there. Outside in the yard there was a piece of timber with a bit of one of those blades embedded in it. Clearly that blade had broken during a cutting operation. I wonder what it sounded like? I wonder if the operator had to go home and change his shorts and take the rest of the day off after...
I've sharpened a two person crosscut saw, set the teeth and swedged the rakers - satisfying to use the tool after when the job is well done. Those teeth are big though, relatively.